Magnetoresistive reader with demagnetization flux guide

ABSTRACT

A magnetic reader comprises first and second shields oriented transversely to a media-facing surface, a magnetoresistive stack located between the first and second shields, and a flux guide. The magnetoresistive stack extends from a proximal end oriented toward the media-facing surface to a distal end oriented away from the media-facing surface. The flux guide extends from the first shield toward the second shield, and is spaced from the magnetoresistive stack at the distal end. The flux guide magnetically couples the distal end of the magnetoresistive stack to the first shield.

BACKGROUND

Magnetoresistive (MR) sensors and related devices have a wide range of applications in non-volatile data storage systems. MR sensors are typically formed as part of a magnetic transducer or read/write head, and can be configured for data storage operations on a variety of different data storage media. The writer uses a write current to generate magnetic flux in a main pole (or write pole), and data are stored by switching the write current as the transducer tracks along a magnetic medium. In particular, the write current determines the flux density and field direction at the tip of the write pole, and the writer generates a sequential bit pattern by defining magnetic domains in the medium according to the flux at the write pole tip.

The reader reads back the bit pattern as a function of a sense current, which depends upon the resistance across the MR sensor. In anisotropic MR (AMR) devices, for example, the volume resistance varies with the external magnetic field, allowing the bit pattern to be decoded from the sense current as the AMR sensor tracks along the magnetic medium. In spin valve sensors, the resistance depends on transition effects such as giant magnetoresistance (GMR) or tunneling magnetoresistance (TMR), and the sense current varies with the relative magnetic orientation of a free layer, where the free layer field rotates in response to the external field (i.e., the bit pattern), with respect to a reference layer, in which the field direction is fixed.

Simple spin valve devices typically utilize a single reference layer, while dual spin valve (DSV) devices have multiple reference layers. Other sensors utilize the colossal MR (CMR) effect, which is characterized by greater signal amplitude but also requires a stronger external field, and can be challenging to achieve with standard magnetic media.

In read head construction, the MR sensor is generally located between first and second read shields, which are oriented transversely to an external media-facing surface and separated from one another by a read gap. In some reader designs the MR sensor extends across the read gap from one shield to the other, and in other designs the MR sensor is spaced from one or both shields by a nonmagnetic material.

In typical stacked transducer designs, the reader and writer structures are formed one on top of the other, usually with the reader first and the writer on top. In merged/stacked configurations, which are generally less common, one of the read shields also functions as a first or bottom return pole for the writer. Alternatively, the reader and writer are formed side-by-side in a substantially coplanar arrangement, with the writer spaced from the reader along the media-facing surface of the transducer.

Bit density is a major consideration in transducer design. In particular, as the bit density (or areal density) increases, the corresponding read and write head structures must be reduced in size. In the case of the reader this affects both the read gap, which is measured between the shields along the media-facing surface, and the stripe height, which is defined along the spin valve, transverse to the media-facing surface. Reduced stripe height and read gap are associated with increased demagnetization fields, which result when flux lines overlap and cross layers of the MR stack, affecting free layer response. As a result, there is a continuing need for MR sensor designs that accommodate smaller reader dimensions and higher areal density, while maintaining response and sensitivity by addressing the effects of demagnetization fields.

SUMMARY

This invention is directed to a magnetic reader. The reader comprises a magnetoresistive (MR) stack located between first and second shields. The MR stack extends from a proximal end oriented toward a media-facing surface to a distal end oriented away from the media-facing surface. A demagnetization flux guide extends from the first shield toward the second shield, and is spaced from the distal end of the MR stack. The flux guide magnetically couples the distal end of the MR stack to the first shield.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an external surface view of a magnetic transducer having a reader with an MR stack.

FIG. 2 is a cross-sectional view of the magnetic transducer in FIG. 1, showing the MR stack with demagnetization flux guide.

FIG. 3A is a cross-sectional view of the MR stack in FIG. 2, in a current-perpendicular to plane (CPP) embodiment with a synthetic antiferromagnetic (SAF) reference layer structure.

FIG. 3B is an alternate cross-sectional view of the MR stack in FIG. 3A, in a CPP embodiment having a different stack orientation and flux guide configuration.

FIG. 4 is a plot of representative hysteresis curves for the reader in FIG. 2, as compared to a baseline design without a demagnetization flux guide.

FIG. 5A is a cross-sectional view of the MR stack in FIG. 2, in a CPP embodiment with a single-layer ferromagnetic (FM) reference layer.

FIG. 5B is an alternate cross-sectional view of the MR stack in FIG. 5A.

DETAILED DESCRIPTION

FIG. 1 is an external or media-facing surface view of magnetic transducer 15 with reader 30 and writer 40. Transducer 15 is oriented about center axis A, along media tracking direction T.

Reader 30 and writer 40 are formed as a number of closely spaced layers, for example by thin film deposition on a slider or other substrate material. In the particular embodiment of FIG. 1, reader 30 comprises first read shield 31, second read shield 32 and MR stack (or MR sensor) 34. Typically, first shield 31 is formed as a bottom shield and second shield 32 is formed a top shield, as shown in FIG. 2, but this designation is arbitrary. In other embodiments, first shield 31 is a top shield and second shield 32 is a bottom shield, depending upon the orientation of MR stack 34 and the other components of reader 30.

MR stack 34 comprises a multilayer magnetoresistive stack or spin valve, which extends along tracking direction T between first (bottom) read shield 31 and second (top) read shield 32. Nonmagnetic insulator (read gap material) 35 comprises a dielectric such as alumina (aluminum oxide, or Al₂O₃), and extends between first and second read shields 31 and 32.

As shown in FIG. 1, writer 40 is separated from reader 30 by an additional layer of dielectric insulator 36, with reader 30 and writer 40 configured for perpendicular data storage operations. Alternatively, transducer 15 utilizes a merged head design in which top read shield 32 also functions as a bottom shield for writer 40. In further embodiments, reader 30 and writer 40 are configured either for perpendicular or longitudinal read and write operations.

Bit density scales with the physical dimensions of reader 30 and writer 40, particularly MR stack 34. Unfortunately, reduced stack dimensions are associated with increased demagnetization effects, as described above, which tend to limit reader sensitivity and the physically attainable density. To address this concern, reader 30 is provided with a demagnetization flux guide to direct stray (demagnetization) flux away from MR stack 34, increasing reader sensitivity and providing for higher areal densities and reduced reader dimensions.

FIG. 2 is a cross-sectional view of magnetic transducer 15, taken along center axis A of FIG. 1. Magnetic transducer 15 comprises reader 30 and writer 40. Reader 30 and writer 40 are positioned to perform data storage operations on magnetic medium 20, which translates in tracking direction T with respect to external (media-facing) surface 51 of transducer 15.

Reader 30 comprises first read shield 31, second read shield 32 and MR stack 34, as described above, with flux guide 50 to reduce demagnetization effects. In the embodiment of FIG. 2, the layers of MR stack 34 are oriented transversely to media-facing surface 51, and generally parallel to first and second read shields 31 and 32. Flux guide 50 extends from second (top) read shield 32 toward first (bottom) read shield 31, and is spaced from the distal end of MR stack 34 (opposite media-facing surface 51) by read gap material 35.

In some embodiments, reader 30 and writer 40 are provided with protective coating 58 at external surface 51. Typical protective coatings include encapsulants, diamond-like coatings (DLCs) and combination thereof, which protect magnetic transducer 15 and prevent hard particle contamination of magnetic medium 20.

In operation of transducer 15, magnetic medium 20 translates in tracking direction T with respect to media-facing surface 51. Writer 40 generates magnetic flux loops that cross media-facing surface 51 into data storage medium 20, in order to lay down a sequential bit pattern.

Reader 30 decodes the bit pattern as a function of a sense current across MR stack 34, where the sense current varies with the external field strength along media-facing surface 51 (that is, with the magnetic domains in the bit pattern). First and second read shields 31 and 32 shield MR stack 34 from stray flux, improving sensitivity to smaller bit patterns and increasing the attainable bit density.

As bit size decreases, however, reader 30 and writer 40 are subject to additional dimensional constraints. With particular respect to MR stack 34, reduced layer thickness increases field overlap and demagnetization effects, ultimately limiting the attainable areal density. Flux guide 50 addresses this issue by directing demagnetization flux away from MR stack 34, providing for smaller stack dimensions without sacrificing reader sensitivity.

FIGS. 3A and 3B are cross-sectional views of reader 30 with demagnetization flux guide 50, in current-perpendicular-to-plane (CPP) embodiments having a synthetic antiferromagnetic (SAF) reference layer structure. In these embodiments, MR stack 34 is formed as a multilayer MR stack comprising seed layer 61, pinning layer 62, multilayer SAF structure 63, spacer/barrier layer 64, free layer 65 and cap layer 66. Multilayer SAF 63 comprises ferromagnetic (FM) pinned layer 63A, coupling layer 63B and FM reference layer 63C.

First and second read shields 31 and 32 extend transversely to media-facing surface 51, separated by MR stack 34 and read gap material 35. MR stack 34 is located between first and second read shields 31 and 32, with proximal (media-facing) end 71 oriented toward media-facing surface 51 and distal (opposite) end 72 oriented away from media-facing surface 51.

In the embodiment of FIG. 3A, demagnetization flux guide 50 is coupled to second (top) shield 32 and extends downward past free layer 65 toward FM reference layer 63C of SAF 63. In the embodiment of FIG. 3B, demagnetization flux guide 50 is coupled to second (bottom) shield 31 and the orientations of MR stack 34 and SAF 63 are reversed, such that flux guide 50 extends upward past free layer 65 toward FM (pinned) layer 63A.

Stripe height H is measured from proximal end 71 to distal end 72 of MR stack 34. Read gap G is measured along the tracking direction, between first shield 31 and second shield 32.

In compact bit spacing configurations, read gap G is limited to a particular width, for example about 100 nm or less. In some of these embodiments, read gap G is limited to about 50 nm or less, and in additional embodiments read gap G is limited to about 30 nm or less. In these dimensional ranges, MR stack 34 is subject to substantial demagnetization field effects, which are addressed via demagnetization flux guide 50.

Flux guide 50 and shields 31 and 32 are typically formed of a soft magnetic material such as NiFe, CoFe or a similar soft magnetic alloy. In some embodiments, flux guide 50 and one or both of read shields 31 and 32 are formed of the same magnetic material, in order to improve flux coupling and field uniformity, or to reduce manufacturing requirements. Alternatively, different magnetic materials are used, for example to provide field shaping.

Flux guide 50 is spaced from MR stack 34 by distal flux gap D at stripe height H, and extends along distal end 72 in order to magnetically couple MR stack 34 to one of shields 31 and 32. Flux guide 50 also extends transversely with respect to media-facing surface 51 along one of read shields 31 or 32, and across a portion of read gap G such that flux guide 50 is spaced from the opposite shield by shield gap S.

In the particular embodiments of FIGS. 3A and 3B, distal gap D ranges from about two to about twenty nanometers (2-20 nm) and shield gap S ranges from about 15-40 nm. These dimensions vary, however, depending on the configuration of MR stack 34 and shields 31 and 32, and on the particular manufacturing steps used to form reader 30. In some embodiments, for example, gaps D and S are formed by chemical vapor deposition (CVD) of nonmagnetic insulator 35, combined with masking, etching and milling of the gap and adjacent structures. In other embodiments, flux gaps D and S are formed using additional techniques such as thin-film deposition or atomic layer deposition (ALD).

In ALD embodiments, the microscopic structure of the flux gap material is defined by a gas phase chemical process in which individual precursors (that is, the molecular components of read gap material 35) are sequentially deposited as a series of monolayer structures formed by self-limiting surface reactions. The ALD process results in conformal flux gap structures that are substantially free of pin holes and other defects, with the gap material chemically bonded to other reader components such as shields 31 and 32, flux guide 50 and MR stack 34 (at distal end 72). The ALD process also improves gap uniformity, with thickness tolerances on the order of 1 nm or less for both distal flux gap D and shield flux gap S.

Seed layer 61 and cap layer 66 are generally formed of materials selected to reduce magnetic couplings between MR stack 34 and first and second read shields 31 and 32, for example Cu, Ni, Fe, Cr, P, Ta and combinations thereof, including NiFe, NiFeCr, Ta/NiFe and NiCrFe/NiFe alloys. The material of seed layer 61 is also selected to enhance the crystallographic structure of the additional layers in MR stack 34, particularly the grain structure, grain size and domain orientation in pinning layer 62.

Pinning layer 62 is deposited adjacent seed layer 61, and is typically formed of a material having a permanent magnetic moment sufficient to pin or fix magnetic orientations within SAF 63. In particular, pinning layer 62 is magnetically coupled to pinned layer 63A, which in turn determines the magnetic orientation of reference layer 63C. Suitable materials for pinning layer 62 include magnetic alloys such as CoPt and CoPtCr, or antiferromagnetic (AFM) materials such as PtMn, MiMn or FeMn.

Pinned layer 63A and reference layer 63C of SAF 63 are typically comprised of ferromagnetic materials such as Fe, NiFe or CoFe, such that the magnetization of pinned layer 63A is determined by ferromagnetic coupling to pinning layer 62. Coupling layer 63B is formed of a non-ferromagnetic material such as Ru, which promotes exchange coupling such that reference layer 63C is antiferromagnetically coupled to pinned layer 63A, and the magnetization of reference layer 63C is oriented oppositely to that of pinned layer 63A.

Free layer 65 is typically formed of a ferromagnetic material in which the magnetic orientation is responsive to an external field across media-facing surface 51, and the resistivity of MR stack varies with the magnetic orientation of free layer 65 as compared to reference layer 63C. This allows reader 30 to read back bit patterns as a function of a sense current that depends on the resistivity of MR stack 34. In GMR embodiments, for example, spacer/barrier layer 64 is formed of a nonmagnetic conductor or spacer, and the sense current across MR stack 34 depends on the giant magnetoresistive effect.

In tunneling (TMR) embodiments, spacer/barrier layer 64 is formed of an insulating tunnel barrier material, and the sense current is a tunneling current. In these TMR embodiments, suitable materials for spacer/barrier layer 64 include dielectric oxides of Al, Mg, Hf, Ta, Nd, Ti or Zr, and combinations thereof.

In the CPP embodiments of MR stack 34 illustrated by FIGS. 3A and 3B, read shields 31 and 32 are typically formed of conducting magnetic materials and also function as electrical contacts for conducting the sense current MR stack 34. In these embodiments, the sense current flows substantially perpendicularly to the layers of MR stack 34, and MR stack 34 extends across substantially all of read gap G, from first read shield 31 to second read shield 32.

In current-in-plane (CIP) embodiments, the sense current contacts are formed on either side of MR stack 34 (that is, on the left and right in FIG. 1), and the sense current flows substantially parallel to the individual layers of MR stack 34. In these embodiments, MR stack 34 is typically spaced from top and bottom read shields 31 and 32 by additional read gap material 35.

The magnetic field orientations within individual layers of MR stack 34 depend on the detailed arrangement of seed layer 61, pinning layer 62, SAF layers 63A, 63B and 63C, spacer/barrier layer 64, free layer 65 and cap layer 66. Typically, individual magnetic orientations are either into or out of (that is, perpendicular to) the planar structure of MR stack 34, but longitudinal magnetic fields are also produced for biasing and other purposes, and surface and edge magnetization effects must also be taken into account.

Magnetic flux lines, moreover, are not constrained to remain within particular layers of MR stack 34, but tend to diverge and stray across layer boundaries, generating both longitudinal and perpendicular demagnetization field components, for example in free layer 65 and along the sides and distal end 72 of MR stack 34. These demagnetization fields tend to increase hysteresis, increasing response time and reducing the angular difference in magnetization direction in free layer 65 with respect to reference layer 63C.

As the dimensions of reader 30 and MR stack 34 are reduced to accommodate higher bit densities, moreover, demagnetization effects increase, further decreasing sensitivity and response. Flux guide 50 limits these demagnetization effects by directing stray flux away from MR stack 34. In particular, flux guide 50 directs demagnetization flux away from distal end 72 of free layer 65, reducing hysteresis and increasing the response of free layer 65.

The configuration of flux guide 50 varies with the corresponding configuration of MR stack 34 and the other elements of reader 30. In some embodiments, for example, flux guide 50 extends from top read shield 32 toward bottom shield 31, as shown in FIG. 3A, and in other embodiments flux guide 50 extends from bottom read shield 31 toward top shield 32. Further, flux guide 50 sometimes extends past free layer 65 to spacer/barrier layer 64 or reference layer 63C, as shown in FIG. 3A, or to a component of SAF 63 such as pinned layer 63A, as shown in FIG. 3B or even past SAF 63 to pinning layer 62.

FIG. 4 is a plot of representative hysteresis curves for MR stack 34, as shown in any of FIGS. 3A and 3B, above, or in FIGS. 5A and 5B, below. Effective resistance R is plotted on the vertical axis and effective field H_(y) on the horizontal, as compared to a baseline design without the demagnetization flux guide. Both axes are unscaled.

Curves 81 and 82 (dashed) are forward and backward hysteresis curves, respectively, for the baseline design, and curves 83 and 84 (solid) are obtained after adding a demagnetization flux guide. The hysteresis area between baseline curves 81 and 82 is substantial, demonstrating demagnetization effects. In particular, demagnetization fields reduce sensitivity by requiring a greater change in effective field H_(y) before a commensurate change in effective resistance R is observed (that is, before the sense current changes). Baseline response curves 81 and 82 are also history-dependent, in that the transition point (in effective field H_(y)) depends not only upon the field strength but also prior magnetic history and field polarity. As a result. In addition the sense current is less responsive to changes in external magnetic fields, and the reader is less sensitive to higher-density bit patterns and smaller field gradients.

Curves 83 and 84, on the other hand, show that the demagnetization flux guide substantially limits hysteresis effects by reducing the demagnetization fields. In particular, hysteresis curves 83 and 84 exhibit a smoother, more continuous transition from low to high resistivity, with improved linearity and reduced free layer rotation. As a result, effective resistance R for curves 83 and 84 is substantially independent of field polarity and prior field excursions, the sense current is more responsive to changes in the external magnetic field, and the MR stack exhibits improved sensitivity to higher-density bit patterns and smaller field gradients.

FIGS. 5A and 5B are alternate cross-sectional views of reader 30 with demagnetization flux guide 50. In the configuration of FIG. 5A, MR stack 34 extends across read gap 35 from bottom shield 31 to top shield 32. In the configuration of FIG. 5B, MR stack 34 is spaced from shields 31 and 32 by additional read gap material.

MR stack 34 comprises seed layer 61, pinning layer 62, reference layer 63C, spacer/barrier layer 64, free layer 65 and cap layer 66, as described above. In these embodiments, however, the multilayer SAF structure is replaced by a single ferromagnetic (FM) reference layer 63C, which is directly ferromagnetically coupled to pinning layer 62, rather than antiferromagnetically coupled to pinned layer 63A via coupling layer 63B as shown in FIGS. 3A and 3B, above.

The single-layer FM reference layer structure of FIGS. 5A and 5B reduces the number of elements (layers) in MR stack 34, reducing reader size and providing for additional increases in areal density with lower manufacturing costs. This contrasts with existing designs, in which a larger SAF structure is required to fix the reference layer orientation and ensure reader sensitivity.

In the particular embodiments of FIGS. 5A and 5B, distal gap D is reduced from about 2-20 nm to about 2-10 nm or less, typically to about 5 nm or less. Shield gap S is similarly reduced, from about 15-40 nm to about 5-20 nm or less, typically to about 5-10 nm. Depending on embodiment, this provides greater flux coupling between MR stack 34 and flux guide 50, further reducing the demagnetization fields and hysteresis effects, and further improving response to small bit patterns and low field gradients.

While this invention has been described with reference to particular embodiments, the terminology used is for the purposes of description, not limitation. Workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention, including the substitution of various equivalents for particular invention elements and adaptation of the invention's teachings to different materials, situations and circumstances. Thus the invention is not limited to the particular embodiments disclosed herein, but encompasses all embodiments falling within the scope of the appended claims. 

1. A magnetic reader comprising: first and second shields oriented transversely to a media-facing surface; a magnetoresistive stack located between the first and second shields, and extending from a proximal end oriented toward the media-facing surface to a distal end oriented away from the media-facing surface; a flux guide spaced from the distal end of the magnetoresistive stack and extending from the first shield toward the second shield, such that the flux guide magnetically couples the distal end of the magnetoresistive stack to the first shield.
 2. The magnetic reader of claim 1, wherein the magnetoresistive stack has a current perpendicular to plane configuration comprising a free layer and a reference layer, such that a resistivity of the magnetoresistive stack depends upon a magnetic orientation of the free layer with respect to a magnetic orientation of the reference layer.
 3. The magnetic reader of claim 2, wherein the magnetoresistive stack comprises a multilayer synthetic antiferromagnetic structure, and wherein the multilayer synthetic antiferromagnetic structure comprises the reference layer.
 4. The magnetic reader of claim 2, wherein the magnetoresistive stack comprises a single-layer ferromagnetic reference layer ferromagnetically coupled to a pinning layer.
 5. The magnetic reader of claim 2, wherein the magnetoresistive stack comprises a cap layer adjacent the first shield and a spacer or barrier layer between the free layer and the reference layer, and wherein the flux guide extends past the cap layer and the free layer at least to the spacer or barrier layer.
 6. The magnetic reader of claim 2, wherein the magnetoresistive stack comprises a seed layer adjacent the first shield and a spacer or barrier layer between the free layer and the reference layer, and wherein the flux guide extends past the seed layer and the free layer at least to the spacer or barrier layer.
 7. The magnetic reader of claim 1, wherein a read gap defined between the first and second shields is about 50 nm or less.
 8. The magnetic reader of claim 7, wherein the flux guide is spaced from the distal end of the magnetoresistive stack by about 2 nm to about 5 nm.
 9. The magnetic reader of claim 8, wherein the flux guide extends from the second shield toward the first shield such that the flux guide is spaced from the first shield by about 5 nm to about 10 nm.
 10. The magnetic reader of claim 1, wherein the flux guide comprises NiFe, CoFe or other soft magnetic materials.
 11. A magnetoresistive device comprising: a free layer extending between first and second opposing ends, the free layer having a free field orientation that rotates in response to an external magnetic field at the first end; and a reference layer spaced from the free layer and extending along the free layer from the first end to the second end, the reference layer having a fixed field orientation with respect to the external magnetic field; a shield for shielding the free layer from stray magnetic flux; and magnetic material extending from the shield along the second end of the free layer and spaced from the free layer at the second end, such that the magnetic material directs demagnetization flux away from the free layer.
 12. The magnetoresistive device of claim 11, wherein the magnetic material extends from the shield past the second end of the free layer and is spaced from the reference layer at the second end, such that the magnetic material directs demagnetization flux away from the reference layer.
 13. The magnetoresistive device of claim 11, wherein the magnetic material is spaced from the second end of the free layer by a nonmagnetic gap material having a thickness of about 5 nm or less.
 14. The magnetoresistive device of claim 11, wherein the shield is comprised of a conducting material for conducting a sense current perpendicularly to a plane of the free layer and perpendicularly to a plane of the reference layer.
 15. The magnetoresistive device of claim 11, wherein the reference layer comprises a single-layer ferromagnetic structure and is ferromagnetically coupled to a pinning layer in order to fix the fixed field orientation with respect to the external magnetic field.
 16. A magnetic transducer comprising: a writer oriented toward a media-facing surface; a reader oriented toward the media-facing surface, the reader comprising: first and second read shields extending transversely from the media-facing surface; a spin valve located between the first and second read shields; a nonmagnetic insulator extending between the first and second read shields; a demagnetization flux guide extending from the first read shield toward the second read shield, such that the demagnetization flux guide is spaced from the spin valve by the nonmagnetic insulator.
 17. The magnetic transducer of claim 16, wherein the spin valve comprises a free layer having a free field orientation and a reference layer having a fixed field orientation, and wherein a resistivity of the spin valve depends on a relative orientation of the free field orientation and the fixed field orientation.
 18. The magnetic transducer of claim 17, wherein the spin valve comprises a pinning layer and wherein the fixed field orientation of the reference layer is fixed by direct ferromagnetic coupling to the pinning layer.
 19. The magnetic transducer of claim 16, wherein the nonmagnetic insulator spaces the demagnetization flux guide from the spin valve by a distance of about 10 nm or less and spaces the demagnetization flux guide from the second read shield by a distance of about 20 nm or less.
 20. The magnetic transducer of claim 19, wherein the nonmagnetic insulator comprises a thin film of aluminum oxide. 